Baltmotors ATV200-D User manual

Brief introduction
The full name of ATV is All-Terrain vehicles. ATV200-D is newlymanufactured by our indus-
tries (group) co.,Ltd..
ATV200-D embodies the experience and essence of world motorcycle technology.It adpots
single-cylinder four-stroke air -cooled engine newly developed by our company,and employs
the devices of carburetor manual clutch,four-speed shifting,and have reverse, PEI ignition,
pressure splash lubrication system,etc,which are good in performance.This ATV is novel and
bright in design,having moved,streamlined model and luxury decoration design,And it meet the
national standard in noise and dirt drainage ,especially it embodies the great power,reliability,
endurance,being an ideal transportation facility for ATV funs.
The correct operation and maintenance are the prerequisites at your safety riding of the
ATV,and also can reduce the fault of the ATV and keep its best performance. So please read
this manual! to understand its basic operation,repair and maintenance methoels .The informa-
tion contained herein all relates to the ATV of the current design and is subject to changes by

IMPORTANT INFORMATION FOR OPERATION
Injury or death could be result from failure to follow WARNING instruc-
tions when you are operating inspecting or repairing theATV.
A CAUTION indicates special precautions that must be taken to avoid
damage to theATV.
ANOTE provides information can make your operation in the ATV easier
or clearer.
WARNING
CAUTION
NOTE
our company according to the demands of market and users without notice .if you have any
questions.Please consult with our motorcycle dealer.We are welcome for you precious advice
and suggestions.Our company has established many service centers (stations,points),with spe-
cially-tranined technical personnel in operation and maintenance ,please contact with our mo-
torcycle dealer and service center(stations,points).Our company consisitantly adheres to the
principle of quality first,users upmost,reputation foremost and be ready to provide you with high
quality service.

Safety information.......................................... Ⅰ
Description and machine identification......... 1
Control functions............................................ 3
Main switch.................................................... 3
Indicator lights ............................................... 3
Handlebar switches ....................................... 3
Start switches................................................ 3
Light switches................................................ 4
Throttle lever .................................................. 4
Speed limiter.................................................. 5
Front brake lever............................................ 5
Rear brake pedal and lever............................ 5
Parking brake ................................................ 6
Shift pedal...................................................... 7
Drive select lever............................................ 7
Recoil statrer ................................................. 7
Content
Fuel tank cap................................................. 7
Fuel cock ....................................................... 8
Seat ............................................................... 8
Storage box ................................................... 9
Front carrier ................................................... 9
Rear carrier .................................................... 9
Rear shock absorber ..................................... 9
Spring preload adjustment ............................ 9
Pre-operation checkes .................................. 10
Front and rear brakes.................................... 10
Fuel ................................................................ 11
Engine oil....................................................... 11
Lubrication oil of gear case ........................... 11
Throttle lever .................................................. 11
Fittings and Fasteners .................................. 12
Lights ............................................................. 12

Switches ........................................................ 12
Battery ........................................................... 12
Tires ............................................................... 12
How to measure tire pressure....................... 12
Tire wear limit ................................................ 13
Operation ....................................................... 14
Starting an engine ......................................... 14
Starting a cold engine ................................... 14
Starting a warm engine ................................. 14
Prewarming.................................................... 14
Drive select lever operation
and reverse driving ......................................... 15
Shifting ........................................................... 15
To start out and accelerate ........................... 16
To decelerate ................................................. 16
Content
Engine break-in ............................................. 16
Accessories................................................... 17
Loading .......................................................... 17
Ride with care................................................ 18
Speed limit valve............................................ 19
Exhaust silencer............................................ 19
Turning ........................................................... 20
Climbing slope ............................................... 21
Riding downhill............................................... 22
Crossing depression...................................... 22
Crossing through shallow water .................... 22
Riding over rough terrain................................ 23
Slipping .......................................................... 23
Periodic maintenance and adjustment ......... 24
Operation manual and tool kit ....................... 24

Periodic maintenance /Lubrication ............... 25
Engine oil....................................................... 27
USE of cooling system ................................. 28
Spark plug inspection.................................... 31
Air filter cleaning............................................ 31
Carburetor adjustment.................................. 33
Idle speed adjustment .................................. 33
Valve clearance adjustment .......................... 33
Throttle lever adjustment ............................... 33
Front and rear brake shoe inspection........... 34
Front brake lever free play adjustment ......... 34
Rear brake adjustment .................................. 35
Clutch adjustment ......................................... 36
Cable inspection and lubrication................... 37
Steering vertical tube lubrication................... 37
Content
Wheel removal ............................................... 37
Wheel installation.......................................... 38
Fuse replacement.......................................... 39
Replacing the headlight bulb......................... 39
Spark arrester cleaning ................................. 40
Cleaning and storage .................................... 41
Cleaning ......................................................... 41
Storage .......................................................... 42
Main data and specification .......................... 43
Maintenance record....................................... 45
Electric wiring diagram .................................. 46

SAFETYINFORMATION
This operation manual includes important safty and maintenance information.When resell-
ing the ATV TO THE NEXT BUYER,the operation manual should be passed on together with it
because the next user also need the manual .Please read the manual carefully before driving
the new .If failed to conform the requirements described in the manual,it will be easy to cause
injuries and deaths.
WARNING
● Read this manual carefully and follow the operating procedures and methods described
in this manual.
● Never operate an ATV without proper training or instruction.
● A child under 16 years old should never operate an ATV.Never allow drive of an ATV by
an individal person if he or she does not have the abilities to operate it safely.
● Always avoid driving an ATV on any paved surfaces,including sidewalks,driveways, park-
ing lots and streets.
● Never operate an ATV in any public street,road or highway,even a dirt or gravel one.
Ⅰ

Ⅱ
● Never drive an ATV without wearing an approved motorcycle helment that fits properly.
You should also wear eye protection(goggles or face shield),gloves,boots,long-sleeved shirt or
jacket,and long pants.
● Nevr consume alcohol or drugs before or while operating this ATV.
● Never operate at speeds too fast.always drive at low speed on dusty surface.
● Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this
maunal.
● Always keep both hands on the handlebars and both feet on the footboards of the ATV
during operation.
● Never operate on excessively rough,slippery or loose terrain unless you have learned
and practiced the skills necessary to control the ATV on such terrain.Always be especially
cautious on these kinds of terrain.
● Always follow proper procedures for turning as described in this manual.Practice turning
at low speeds before attempting to turn at faster speeds.Do not turn at excessive speed.
● Never drive the ATV on hills too steep for the ATV or for your abilities.Practice on smaller
hills before attempting larger hills.

Ⅲ
● Always follow proper procedures for climbing hills as described in this manual.Check the
terrain carefully before starting up any hill.Never climb hills with excessively slippery or loose
surfaces.Shift your weight forward.Never open the throttle suddenly or make sudden gear
changes.Never go over the top of a hill at high speed.
● Always follow proper procedures for going down hills and for braking on hills as described
in this manual.check the terrain carefully before starting down any hill .Shift your weight backward.
Never go down a hill at high speed .Avoid going down a hill at an angle that would cause the
vehicle to lean sharply to one side .Go straight down the hill where possible.
● Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces,shift your weight to the uphill side of the
ATV.Never attempt to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground .Avoid crossing the side of a steep hill if
possible.
● Avoid crossing the steep hills.
● Always use proper procedures if you stall or roll backwards when climbing a hill.To avoid
stalling,use proper gear and maintain a steady speed when climbing a hill.If you stall or roll
backwards,follow the special procedure for braking described in this manual.

Ⅳ
● Always check for obstacles before operating in a new area.Never attempt to operate over
large obstacles,such as large rocks or fallen trees.Always follow proper procedures when oper-
ating over obstacles as described in this manual.
● Always be careful when skidding or sliding.Learn to safely control skidding or sliding by
practicing at low speeds and on level ,smooth terrain .On extremly slippery surfaces,such as
ice,go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
● Never operate an ATV in fast flowing water or in water deeper than that recommended in
this manual.Remember that wet brakes may have reduced stopping ability.Test your brakes
after wiping water away.If necessary,apply them several times to let fricting dry out the linings.
● Always be sure there are no obstacles or people behind you when operating in reverse.
When it is safe to procceed in reverse,go slowly.Always use the size and type tires specified in
this manual.Always maintain proper tire procedure as described in this manual.
● Never modify an ATV through improper installation or use of accessories.
● Never exceed the stated load capacity for an ATV.Cargo should be properly distributed
and securely attached.
● Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer.

Ⅴ
Allow greater distance for braking.
● Improper handing of gasoline can cause fire and can cause injuries and deaths and
other serious accident. So do not refuel right after the engine has been running and is still
every hot .Never refuel while smoking ,or while in the vicinity of sparks ,open flames ,or other
sources of ignition,when transporting the machine in another vehicle,be sure it is kept upright
and that the fuel cock is in the”OFF”position,otherwise fuel may leak out of the carburetor or
fuel tank.
● Starting or running the engine in a closed area will cause the breakdown.And exhaust
fumes are poisonousus and may cause loss of consciousness and death within a short time.
Always operate your machine in an area with adequate ventilation.

1. Front wheel
2.Headlight
3.Shift pedal
4.Fuel cock
5.Cushion
6.Taillight
7.Rear wheel
8.Spark arrester
9.Carturetor
10.Rear brake pedal
11.Bumper
DESCRIPTION AND MACHINE IDENTIFICATION
12.Clutch
13.Throttle lever
14.Fuel tank cap
15.Main switch
16.Parking brake
17.Rear brake lever
The machine you have purchased may differ
slightly fron those shown in the figures of this manual
for progress or other change.
-1-
123 4 5 6
78 9 10 11
13 14 15 1612 17

Identification numbers record
When ordering spare parts from a our dealer or for reference in case the vehicle is stolen Record ,
vehicle identification number in the spaces provided for assistance.
1.VEHICLE IDENTIFICATION NUMBER:
Vehicle identification number
The vehicle identification number is stamped on crosstube of pedestal.
-2-

Indicator lights
Reverse indicator light“R”
Main switch
Functions of the respective switch positions are
as follows:
ON:
Engine can be started only at this position and
the headlight and taillight come on when the light
swithc is on.
OFF:
All electrical circuits are switched off.The key
can be removed in this position.
This indicator light comes on when the trans-
mission is in reverse.The light is blue in color.
Neutral indicator light“ ”
This indicator light comes on when the trans-
mission is in neutral.
High beam indicator light“ ”
This light is yellow in color .It comes on when
the head light and high beam light is on.
Handlebar switches
Engine stop switch
Make sure that the engine stop switch is in
the “ ” position.The engine stop switch
controls ignition and can be used at all times to
stop the engine,especially in an emergency.The
engine will not start or run when the engine stop
switch is turned to“ ”.
Start switch
The starter motor cranks the engine when this
switch is pushed.
See starting instructions prior to starting engine
(see page for details).
If the starter switch is pushed with the
N
OFF ON
-3-
CONTROL FUNCTIONS

-4-
main switch“ ”and the engine stop
switch “ ”,the starter motor will be activated
but the engine will not start.To start the engine ,be
sure to set the engine stop switch at“ ”.
Lights swtich “LIGHTS”
Turn the switch to“ ” for the low beam and
taillight.
Turn te switch to “ ”for the hight beam
and taillight.
Throttle lever
Once the engine is running ,movement of the
throttle lever will increase the engine speed.Adjust
the speed of the machine by changing the throttle
position.Because the throttle is spring-loaded,the
machine will decelerate,and the engine will return
to an idle any time the hand is removed from the
throttle lever,Before starting the engine ,check the
throttle to be sure it is operating smoothly .Make
sure it returns to the idle position as soon as the
lever is released.
Check the operation of the throttle lever before
starting the engine.If it does not work smoothly,check
1.Lights switch“LIGHTS”
2.Engine stop switch“ ”“ ”
3.Start switch“ ”
1.Neutral indicator light“ N ”
2.Reverse indicator light“R ”
3.Hight beam indicator light“”
4.Water temperature indicator“”
①③②
④
①
②
③

for the cause.Correct the problem before riding the
ATV.Consult a our dealer if you can’t find or solve the
probem yourself.
1.Throttle lever 2.Front brake lever
Speed limiter
The speed limiter keeps the throttle from fully
opening,even when the throttle lever is pushed to
the maximum.Screwing in the adjusting screw lim-
its the maximum engine power available and de-
creases the maximum speed of the ATV.
1.Locknut 2.Adjusting screw
a.12mm(047in)
CAUTION
Do not turn the speed adjusting screw out more
than 12mm.Always make sure the throttle lever free
play is adjuted to 3-5mm.
Front brake lever
The front brake lever is located on the right
handlebar.Pull it toward the handlebar to apply the
front brake.
Rear brake pedal and lever
The brake pedal is located on the right side of
-5-
①②
①②

-6-
the machine and the brake lever is located on the left
handlebar.Pull the lever toward the handlebar or tread
slow the pedal to apply the rear brake.
Parking brake
When you have to start the engine or park the
machine,especially on a slope,use the parking brake
1.Rear brake pedal
engine,This could cause loss of control or a
collision.
The barke could overheat if you ride the ATV
without releasing the parking brake.You could lose
braking performance which could cause an accident
.You could also wear out the brakes prematurely.
Apply the rear brake lever and push down the
lock plate to apply the parking brake,squeeze the
rear brake lever to release the parking brake.
CAUTION
the ATV could start moving unexpectedly if the
parking brake is out of function before starting the
①
1.Front brake lever 2.Lock plate
①
1.Lock plate
①
②

HOWTOAVOID THE HAZARD
Always set the parking brake before starting the
engine.Always be sure the parking brake have been
released before you begin to ride.
Shift pedal
This machine is equipped with a constant mesh
4-speed transmission .The shift pedal is located on
the left side of the engine.Reverse is at the bottom
position. 4-3-2-1-N-R
CAUTION
Don’t start the engine in non-neutral or without
setting the parking brake system.
Put the transmission in neutral and set the park-
ing brake before starting the engine.
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
-7-
The drive select lever is used for driving the ma-
1.Shift pedal N.Neutral
①
chine either forward or in reverse.Refer to page for
drive select lever operation.
①
1.Fuel tank cap

-8-
ON:
If the lever is in this position,fuel flows to the
carburetor.Normal riding is done with the lever in
this position.
Fuel cock
The fuel cock supplies fuel from the fuel tank to
the carburetor.
OFF:
If the lever is in this position ,fuel will not flow.
Always turn the lever to this position when the en-
gine is not running
RES:
This indicates reserve.If you run out of fuel while
riding,turn the lever to this position.After refuelling,
return the fuel cock lever to the “ON”position.
Seat
To remove the seat,pull the seat lock lever up-
ward and pull up the seat at the rear.
To install the seat,insert the lobes on the frame
and push down the seat at the rear,you should pay
attention to make sure that the seat is securely
fitted.